1. Fixing Poor Control Surface Performance on a Transonic Missile – A Case Study of Combining Cost-effective Wind Tunnel Testing and CFD Analysis CP Crosby and SG Gobey Aerodynamics Department Kentron South Africa

2. Methods for Aerodynamic Design “Classical” exact analytical Semi-empirical database methods Computational Fluid Dynamics Wind-tunnel testing Discrete methods with clearly defined boundaries?

3. Combining CFD and Experiments “Conventional” view: use wind-tunnel to validate CFD, then use calibrated CFD to perform further studies Very slow, very expensive, very narrow view Why do CFD when good tunnel results already exist?

4. What Is “Quality”? CFD good practice stipulates measures to be taken to ensure good quality CFD Good quality CFD is very expensive. Is it always necessary? Does good quality CFD necessarily ensure good quality design? Quality vs. quantity trade-off, which will give better final design? Performance and quality of design is a more meaningful metric than quality of CFD analyses

5. A Real Life Design Problem Transonic (mostly subsonic) missile with canard control User requirements: –Very high manoeuvrability –Strict packaging dimensions –Low hinge moments

6. Problem: Insufficient Elevator Power WT test in concept phase, 1:13 scale model in blow-down wind-tunnel, insufficient elevator effectiveness No CFD capability available, revise design empirically Performance improved, but still unsatisfactory Probable cause: –Low Reynolds number –Poor profile accuracy

7. Problem: Design Flaw, Not Testing Artifact Highly detailed test of 30% model in transonic tunnel

8. Understanding The Flow Relatively “crude” simplified CFD-Fastran model, only 190 000 cells

9. Baseline CFD Confirms Problem Even much simplified CFD captures poor performance

10. CFD Aids Understanding of Flow Problems Premature flow separation due to incidence and deflection Nose upwash aggravates separation Interference due to close spacing

11. Fixing the Problem Thanks to improved understanding, mostly from qualitative inspection of CFD flow fields, design is easy to improve Design tweaked to get better looking picture Increase control surface leading edge sweep angle LE sweep reduces adverse interference on fixed canard Increased gap also reduces interference Boundary layer fence on fixed canard helps

12. Much Prettier CFD Pictures After Mods

14. But Pretty Picture Also Gives Better Forces

15. Confirm With “Crude” Low-speed WT Test Big chances taken with simplified CFD Need to confirm independently CFD suggests non-subtle flow, try cheap WT test WT approximations suggested by CFD: –Low Mach-number (cheaper tunnel) –Simplified aerofoils –“Coke tin & aluminium tape” model modifications Simplified CFD and WT test only practical because of: –Cross-confirmation –Confirmation from later detailed test, which acts as a “Safety Net” Simplified test indicates BL fence was a bad idea, CFD confirms this

16. Low Mach Number Can Be OK Check validity with CFD before WT testing

17. Simplified Aerofoils OK at Low AR Check validity with CFD before WT testing

18. Low Speed Test Confirms Improvement

19. Detailed Transonic WT Test Gives Further Confirmation of Improvement

20. Conclusions Rough WT testing can mislead, use CFD to check Rough CFD can capture most important characteristics of a complex flow field – this may be sufficient Qualitative CFD is very valuable for understanding complex flows, very good for improving designs Characterisation WT test makes a good quality “safety net”, allows earlier CFD and WT testing to take short-cuts Increased quality risk may be more acceptable if CFD and experimental work is integrated Aerodynamic designer, WT test engineer and CFD practitioner need to work ver closely together CFD can lead down blind alleys, even rough WT testing can rectify this Only quality of the final design matters